OPAL-RT Power Hardware-In-the-Loop presentation

www.opal-rt.com

Alexandre Leboeuf, Carl Bisaillon, Pierre-François Allaire 01-22-2015

Power HIL (P-HIL):

A Revolution in the Industry

http://www.opal-rt.com



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Your Hosts

Presenter Pierre-François Allaire Sales & Marketing Director OPAL-RT TECHNOLOGIES

Presenter Alexandre Leboeuf Integration Team Leader OPAL-RT TECHNOLOGIES

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Presenter Carl Bisaillon Support Team Leader OPAL-RT TECHNOLOGIES

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Presentation Outline

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P-HIL Introduction & Benefits

P-HIL Applications & Amplifiers Types

P-HIL Case Studies

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Partners & OPAL-RT Solutions

P-HIL Stability Analysis


Conclusion

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1 2 3 4 5



P-HIL Case Studies

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Conclusion

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HIL or CIL (Controller-in-the-Loop) simulation is a real-time plant model (grid …) interfaced to a piece of hardware under test usually with low-power signal interfaces

Hardware-in-the-Loop (low power interface cases)

HIL or CIL (Controller-in-the-Loop) Relay with IEC 61850 …

Or +- 10V inputs

Hardware under test

Real control, protection devices and communication systems

SCADA (SPS)

DNP3, IEC …104

OPTIONAL LOW-POWER Signal conditioning (+- 1 to 10V, few mA) Optical fibers and communication systems

Real-Time

Simulator

HVDC FACTS uGRID Motor drive

PV, Wind gen

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In some cases, high-voltage and high curent interfaces are required.

Hardware-in-the-Loop (high-power interface cases)

HIL or CIL (controller –in- the-Loop)

Relay with 120V and

50A inputs

Hardware under test

Controller with high

current and high-voltage

inputs

Real devices

2Q Low-Power High-voltage

and high-current

amplifiers

High-voltage (60 to 200V) and high-current (5A to 100A) high-frequency and high accuracy amplifiers are required to interface with some controllers and protection systems. The power rating is relatively low and the amplifier load does not influence the simulation.

Low Power Feedback signals Optional signal conditioning

Real-Time Simulator

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PHIL simulation is the integrated simulation of a complete system with one part simulated numerically and the other part using real devices.

Power Hardware-in-the-Loop

Real devices

Under Tests

The amplifier must have the capability to feed the device under test and to absorb power generated by the devices.

The amplifier loads will influence the global simulation.

PHIL 2Q or 4Q POWER

AMPLIFIERS

with optional coupling inductors and transformers

Voltage and Current Feedback

INVERTER

MOTOR

PV system

Wind turbine

uGRID

Other…

Real-Time

Simulator

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High-fidelity real-time power electronics and power system plant models combined with a quality amplifier can match the performance of a dynamometer or analog bench to achieve a 90% confidence-level that the system will perform as expected.*

• PHIL allows developers to test a wider range of characteristics than analog benches or dynos with less maintenance and setup time.

Allowing robustness of the hardware under test over a wider variation of parameters, characteristics and faults.

• In addition to interacting with the hardware, PHIL simulators are often used to simulate communication networks (CAN,DNP3, ARINC, 61850, others).

Allowing Integration of multiple protocols/systems into a single system.

• A PHIL simulator creates a robust, flexible, versatile, and reliable system

Allowing multiple experiments for multiple programs or research.

Power Hardware-in-the-Loop: Benefits

*Source: Delphi

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Power Hardware-in-the-Loop: Benefits: Complementary tools to SIL, HIL and DYNO testing

SIL (software in

the loop) Fully numerical

off-line/fast parallel

simulation

HIL can be used for

very large-scaled system

simulation not possible with DYNO or PHIL

RCP or actual controllers

DYNO Specialized Analog benches systems

RCP or actual controllers

• RCP+ DYNO: component testing • Emulated mechanical system using the dyno and the

simulated torque • Use of actual motors and inverters for maximum

accuracy • Final testing but with limited functionalities

Controllers implemented in software

• RCP+PHIL: system aspects • Emulated Power Grid/microGrids or on-board

generation systems and loads (ship, aircrafts, automobiles) to analyze interactions between several subsystems

• Each subsystem • Can be the actual systems operating under

normal voltages and power rating • Or scaled-down analog models • Or emulated PHIL models

• Enable to make power tests without detail models (black box)

• Enable to make tests impracticable or too risky to do with the dyno (faults, over-speed …)

• Enable inverter thermal testing without actual motors or complex systems

PHIL Analog benches

with large grid emulation

Model validation & parameter identifications as required for HIL and SIL

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1 2 3 4 5


P-HIL Applications

& Amplifiers Types

P-HIL Case Studies

6




Conclusion

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PHIL Applications

Grid Applications • Grid Emulator (50, 60, 400 Hz)

• Grid Load

• PV-Inverter Emulation

• Wind-Generator Emulation

• Grid Inverter Emulation

• Microgrid Applications

Motor Applications • Motor / Generator Emulator

• Drive Inverter Emulator

• Frequency Inverter Emulator

Aerospace / Military • 400 Hz Supply Grid Emulator

• DC-Supply Emulation

• 400 Hz Aerospace Device Emulator

• AC-DC Coupling Emulator

Automotive Applications • Electrical Drive Train Emulation

• Battery Emulator

• Drive Inverter Emulator

• Motor Emulator

• eVehicle Applications

• eVehicle Charging Station Emulator

• Test Bench for Charging

Transportation • Supply Grid Emulator

• Machine Emulator

• Inverter Emulator

• Electrical Drive-Train Emulation

Courtesy of

EGSTON

Model validation & parameter identifications as required for HIL and SIL

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Power Hardware-in-the-Loop: Amplifiers

PHIL 2Q or 4Q POWER

AMPLIFIERS

with optional coupling inductors and transformers

Voltage and Current Feedback

INVERTER

MOTOR

PV system

Wind turbine

uGRID

Other…

For PHIL applications, OPAL-RT’s simulators can be delivered with standard or custom amplifiers that meet the most demanding requirements with

• Scalability: few hundred watts to megawatt

• 2Q (power generation) and 4Q mode (generation and absorption)

• High accuracy, low distortion and low phase lag

• Low or high bandwidth depending on the applications

Real-Time

Simulator

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Applications vs Amplifier Types

2Q Amplifier Generates Power : • When simulating PV cells

• When simulating fuel-cells

• When output is connected to passive resistive loads (power factor close to 1)

• When output is connected to relays or controller with high-current inputs (HIL mode)

4Q Amplifier Generates and Absorbs Power: • When driving active loads (ex. : motor/generator)

• When emulating a grid

• When emulating a load

• When emulating a battery (energy supply and charging mode)

• When connected to capacitive or inductive loads (low power factor)

Amplifier design depends a lot on the type of loads and the capability to absorb active and reactive power and to return the energy to the grid

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Applications vs Amplifier Types

AC AMPLIFIER: (monophase or triphase)

• When emulating a grid(4Q)

• When emulating AC motors(4Q)

• When connected to AC motors(4Q)

• When connected to AC/DC converters(4Q)

• When simulating a DC/AC controller(4Q)

DC AMPLIFIER: • When simulating PV-cells(2Q)

• When simulating fuel-cells(2Q)

• When connected to DC/AC controllers(4Q)

• When simulating an AC/DC controllers(4Q)

• When simulating and/or connected to a battery(4Q)

In most cases amplifiers with DC and AC capability up to the maximum specified bandwidth will be used to reproduce DC current transients during faults simultaneously with electromagnetic transients that will be applied on equipment under tests and to increase overall system fidelity, bandwidth and stability. Case-by-case analysis must be performed.

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1 2 3 4 5



P-HIL Case Studies

6




Conclusion

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Case Study: NITECH Assembly

SIMULATED:

• 3-phase grid with loads

• Two SVRs

• One SVC

CONNECTED:

• 18 kW amplifier

• Load

• Battery emulator

• Two DC power supplies

• Wind turbine emulator

• PV emulator

Power Grid Emulator MicroGrid Emulator with

actual equipment

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Case study: NITHECH Smart Grid project (Japan)

Modern distribution systems with several active loads and storage systems require advance voltage controllers

• The goal is of PHIL experiment are

• To test several Volt & Var controller logic using real equipment (PV, FC, micro wind turbines, storage equipment)

• To develop controllers

• To analyse various steady-state and fault conditions

Needs :

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Case Study: NITECH PHIL Setup

Supervision

PV Power Plant

EMULATORS (Source – Load – Wind Farm)

Wind Farm

Industry (load)

AC Experimental grid

Real Time simulation

Computer network

18 kVA Power

amplifier

EMULATORS (PV – Storage)

Battery & Charger

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Case Study: NITECH – Amplifier Connection

AMPLIFIER CONNECTION

VOLTAGE CONTROL

• Vu, Vv, Vw

• 1 step delay

CURRENT RESPONSE

• Iu, Iv, Iw

• 1 step delay

AMPLIFIER RESPONSE

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Case Study: Japanese Smart House Project

In a Smart House, the energy generation, energy consumption control and energy storage are all integrated, with individual components.

The goal of PHIL experiment is • To ensure control logics for an adequate energy supply at all times

and also minimize the number of storage units needed, because rechargeable batteries are still a high cost factor

• To analyse the effect of power grid transients on house electronic • To analyse interactions between houses

Needs :

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Smart house has regenerative energy installations such as photovoltaics, solar thermal devices, wind power and energy storage. The interaction between houses and the distribution network must be carefully analysed

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2 kVA DC Amplifier

Real-Time Simulation Time Step 50 us

REAL HOUSE

Real house

box added

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Needs:

• To test a 3-Phase BLDC motor sensorless controller with trapezoidal back EMF at power levels lower than 100W in steady state.

• The PHIL bench needs to generate and absorb power like a real DC motor.

• Open-Circuit and Short Circuit faults required. • Possibility to reuse the hardware in future application (versatility and

upgradability).

Case Study: Plastic Omnium - France 3-Phase Electrical Motor PHIL – 1200 W Setup

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Image source: http://www.mpoweruk.com/motorsbrushless.htm

Consulted 01/19/2015

Case Study: Plastic Omnium 3-Phase Electrical Motor PHIL – Actual Circuit

http://www.mpoweruk.com/motorsbrushless.htm


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Image source: http://www.mpoweruk.com/motorsbrushless.htm

Consulted 01/19/2015

Case Study: Plastic Omnium 3-Phase Electrical Motor PHIL Schematic

OP4500 HIL simulator

The FPGA motor models of the OP4500 simulator will control the amplifier to have an accurate simulation of the motor back EMF and impedance. FEA based motor model can be used

Actual Controller

inverter under test

Motor Emulator Real RL impedance for each branch of the motor to simulate motor inductance

KEPCO 4Q Amplifier



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BLDC Motor 3 Phases motor of 100W

• Real-Time simulation of the Motor on FPGA

Max PWM Frequency: 20Khz

Time-Step: 500 ns

Model vs theoretical precision within 1%

• Amplifier 20V-20A Kepco (BOP 20-20ML)

Nominal Power 400 Watts (4Q)

Loads connected in Delta or Star

• Possibility to perform multiple faults: Short-Circuit (Phase-Phase)

Open-Circuit per phase

Short Circuit (Phase-Battery)

• Programmable Loads

Case Study: Plastic Omnium 3-Phase Electrical Motor PHIL – 1200W Setup

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Case Study: L2EP

• Studies on impact of energy storage systems, in terms of efficiency, quality and services on the network

• Studies of new architectures : microgrid, island networks

• Production sources & storage systems coordination, in order to optimize quality and stability of embedded networks

Electrical Engineering Laboratory of Université des Sciences et Technologies de Lille, Arts et Métiers ParisTech, Ecole Centrale de Lille, Hautes Etudes d'Ingénieur

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http://l2ep.univ-lille1.fr/plateforme/

Case Study: L2EP – U. Lille, France Circuit Under Analysis

Multi Terminal High Voltage DC grid




29 29 http://l2ep.univ-lille1.fr/plateforme/

Case Study: L2EP – U. Lille, France PHIL Setup




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Case Study: AIT SmartEST Laboratory - Austria

For development and research, AIT offers unique opportunities for customers and project partners to optimize their products and control strategies directly at this advanced facility, accompanied by qualified experts in order to shorten the time-to-market of new products.

• Developing and testing PV controller • Testing overall performance of PV systems as per standards • Analyzing interactions between systems and with the distribution system

under steady-state and fault conditions

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Case Study: AIT SmartEST Laboratory

OPAL-RT Real-time simulator

GRID SIMULATION

• 2 independent high bandwidth Grid Simulation Units: 0 to 480 V 3-phase, 800 kVA • 3 independent laboratory grids, which can be operated in grounded/isolated mode • 3-phase balanced or unbalanced operation • Capabilities to perform LVRT (Low Voltage Ride Through) and FRT (Fault Ride Through) testing DC SOURCES 5 independent dynamic PV-Array Simulators: 1500 V, 1500 A, 960 kVA

Adjustable loads for active and reactive power

Line impedance emulation

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1 2 4 5



P-HIL Case Studies

6




Conclusion

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PHIL Stability Analysis

• Closed-loop system may become unstable under certain conditions • Instability caused by delays may damage equipment or reduce simulation

accuracy • Stability depends on:

• Ratio of load power over short-circuit power of the feeder • Type of load • Damping of source impedance • Power amplifier bandwidth • Simulator’s sampling frequency • Use of current feedback filter

PHIL simulation equivalent circuit

Determining the best method to ensure system

stability and maximum accuracy must be done on

a case-by-case basis

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PHIL Stability Analysis

Instability caused by the interaction of: • Lsource (linear gain with a phase of −𝜋 2 )

• L//R filter and voltage amplifier (Limit gain, add phase lag)

IO time delay (adds linear phase lag)

Type of load (higher power, higher gain) • Resistive (No phase effect)

• Inductive (Reduce Lsource phase & gain)

• Capacitive (Increase Lsource phase & gain)

Current feedback filter (Limit gain at fc)

+ -

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PHIL Stability Analysis Conclusions

Bode Diagram • Stability becomes gain dependent

when phase reaches 0

• Maximum stable load (gain ≤ 1), determines max load power

• Lower sample time increases the simulation stability and accuracy

• Cut all the frequencies beyond a phase gain of -π

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Detailed Information on PHIL Stability Analysis

One among many outcomes :

http://www.sciencedirect.com/science/article/pii/S1569190X11000566




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1 2 4 5



P-HIL Case Studies

6




Conclusion

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Power Amplifier Partners

This high power AC and DC test system covers a wide spectrum of AC and DC power applications at an affordable cost. Using state-of-the-art Pulse Width Modulation (PWM) switching techniques, the RS series combines robustness and functionality in a compact, floor-standing chassis.

http://www.ametek.com/



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EGSTON provides a new compact Digital Amplifier Series (EGSTON COMPISO) with high bandwidth output signals. The COMPISO (Ultra Compact Bidirectional Multi-Purpose Inverter with Sinusoidal Output) is a compact high efficient digital amplifier family. The modular series is optimally suited for building up DC-DC, DC-AC, AC-DC as well as AC-AC converter systems in the power range of 120kW up to 1 MW. The COMPISO can be used in many different applications.

http://www.egston.com/en/index.php



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Puissance + proposes innovative, high-range, reliable and accurate programmable power solutions in AC, DC, AC+DC. They can be standard or made according to specifications. Puissance + experience in the generation, absorption and measures in low and high power allows us to test or simulate all types of generators, power sources and charges for laboratory, production and embedded applications.

http://www.puissanceplus.com/en

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Programmable, Reconfigurable Units for the swift realization of Research, Development and Test setups for Power Applications. The Modules are modular and can combine units for AC/DC, DC/DC and motor drives in 5, 15 and 90 kW power ranges.

http://www.triphase.be/



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OPAL-RT Solutions

• OP5600 (12 CPU cores, 1 VIRTEX 6)

IO and EtherCAT

• OP4500 (4 cores, 1 KINTEX 7)

IO, EtherCAT and ORION

• OP5607 (12/32 CPU cores *, 1 VIRTEX 7)

IO, FPGA motor modeling and cascading of

units

• OP7000 (12/32 CPU cores*, 1 to 4VIRTEX 6

IO, Multi-FPGA and FPGA motor modeling * Using external PC

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OPAL-RT in Brief

Our solutions cover the complete spectrum of power system analysis and studies

ePHASORsim Real-Time Transient Stability Simulator 10 ms time step

HYPERsim Large Scale Power System Simulation for Utilities & Manufacturers 25 µs to 100 µs time step

eFPGAsim Power Electronics Simulation on FPGA 1 µs to 100 ns time step

1 s (1 Hz)

10,000

2,000

1,000

500

100

10

0

10 ms (100 Hz)

50 µs (20 KHz)

10 µs (100 KHz)

1µs (1 MHz)

100 ns (10 MHz)

10 ns (100 MHz)

20,000

Period (frequency) of transient phenomena simulated

Number of 3-Phase Buses

eMEGAsim Power System & Power Electronics Simulation Based on Matlab/Simulink and SimPowerSystems 10 µs to 100 µs time step

Today’s Subject

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Choosing the Right Amplifier

• Power rating

• Output voltage/current limit

• Ripple, THD, DC offset,…

• Bandwidth

• Latency

• AC application • Monophase

• Three-phase

• DC application

• 2Q or 4Q

• Communication (EtherCAT, Optic Fiber, AIO, …)

• Emulators • Motor/Generator module

• PV, wind turbine …

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1 2 4 5



P-HIL Case Studies

6




Conclusion

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Conclusion

OPAL-RT has the expertise to help you find the right tools for your PHIL application.

Our Integration Experts can help you achieve your goal by designing your PHIL testing bench and our Field Application Engineers can bring their experience to the field to ensure your PHIL application runs like a charm.

Power Hardware-in-the-Loop should be considered as a complementary tool to SIL, HIL and DYNO testing and not as a replacement of these tools and method.

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Upcoming Events

Distributech, San Diego – February 3-5, 2015 Booth 813

http://opal-rt.com/events/distributech-2015

APEC, North Carolina – March 15-19, 2015 Booth 730

http://opal-rt.com/events/apec-2015

Visit our event page to learn where to meet OPAL-RT TECHNOLOGIES

http://opal-rt.com/events














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Thank you for your attention

Q&A

The PDF version of the P-HIL presentation will be available shortly on

http://opal-rt.com/events/past-webinars






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OPAL-RT Power Hardware-In-the-Loop presentation